Metal clad door and method of manufacturing same



T. BEYRLE Dm w, m5(

METAL CLAD DOOR AND METHOD OF MANUFACTURING SAME Filed MaICh 4, 1931 2 Sheets-Sheet 1 Patented Bec. 10, 1935 METAL CLAD DOOR AND METHOD OF MANUFACTURING SAME Thomas Beyrle, Vernon, Calif.

Application March 4, 1931, Serial No. 519,972

13 Claims.

My invention relates to a door, and more particularly to a metal clad door of the reproof type and a method of manufacturing the same.

It is desirable because of the ease of its assembly and the economy of its manufacture to form such a re resisting door with a wooden frame and panels o'f wood or fire resisting material. It is a corresponding purpose of my invention to provide a re resisting door which inu cludes a metal clad wooden frame and metal clad panels of wood or fire resisting material.

It is a further object of my invention to provide a door of the 'character described which will not be damaged by exposure to the elements.

If a door having wooden elements and hermetically sealed in metal is subjected to considerable heat, the partial combustion of the Wood generates gas which exerts upon the metal sheathing a pressure Which tends to deform or split it.

It is an object of my invention to provide a metal clad door which includes venting means for the escape oi gases generated by the application of heat to the members of which the door is composed.

It is another object of my invention to provide a metal clad door in which some of the joints between adjacent covering elements are concealed by a molding.

It is considerably more convenient and economical td provide the metal covering for the door frame in a plurality of sections and to secure these sections together after they are assembled upon the door frame. If the inished door is to have a sightly appearance, it is imperative that the connections of the various metal elements covering the door frame be inconspicuous.

It is a corresponding object of my invention to provide a metal clad door in which the co'vering members for the frame are so joined that the junctures are invisible.

It is also an object of my invention to provide a door of the class described Which is sightly in appearance, economical to manufacture, and easy to assemble.

It is still another object of my invention to provide a method of manufacturing such a door which includes the steps of assembling metal members around a supporting frame, joining said members together and concealing the joints so formed.

More speciiically, it is an object of my invention to provide a method of manufacturing a door having a supporting structure and a metal envelope which includes the steps of forming grooves in the supporting structure, overlapping the elements of said metal envelope over said grooves, Welding the elements together at their overlap, depressing the joint into the groove, and

filling the depression With a filling medium to conceal the joint.

In the following speciiication I shall describe one embodiment of my invention which is capable of performing the foregoing objects, and 5 others, some of which will be made evident hereinafter. This disclosure may be more readily understood by a reference to the accompanying drawings in which,

Fig. 1 is a perspective view of a` portion oi a 10 door embodying my invention.

Fig. 2 is a section on the plane 2-2 of Fig. 1.

Fig. 3 is a section on the plane 3 3 of Fig. 1.

Fig. 4 is an enlarged view of the joint between the frame covering members of the door of my 15 invention.

Fig. 5 is a perspective view of the upper left hand corner of the frame of the door shown in Fig. l.

Fig. 6 is a perspective view of the metal sheath 20l for a portion of the frame structure shown in Fig. 5.

Fig. 7 is a perspective View of the cooperating metal sheath for another portion of the frame structure shown in Fig. 5. 25

Fig. 8 is a perspective View of the same metal member illustrated in Fig. '7 with its end bent to its nal form.

Referring to the drawings, which are for illustrative purposes only, the numeral II of 30 Fig. 1 indicates the door of my invention Which includes a Wooden frame I2 best illustrated in Fig.

5. The frame I2 comprises horizontal wooden members I3 and vertical wooden members i4 which are connected by the insertion of a tongue 35 I5 provided at each end of each of the horizontal Wooden members I3 in a groove I6 formed in the side of each of the vertical wooden members I4 at the ends thereof. Each of the horizontal Wooden members I3 and the Vertical wooden 40 members I4 of the frame I2 is provided with a recess Il on its inner face. These recesses Il are adapted to receive the edges of a panel member I8.

The panel member I 8 comprises a sheet or panel 45 I9 preferably formed of asbestos or other re resisting material, and twoi metal sheets 20 and 2 I, one secured by any suitable cementing medium on each side of the panel I9. As illustrated in Fig. 2, the dimensions of the metal sheets 26 50 and 2| are substantially equal to the dimensions of the panel I9, so that the entire area of the panel I9 is covered. The panel I9 and the metal sheets 20 and 2l are secured together also by rivets 22 extending through the metal sheets 29 55 and 2l and the panel I9 near the edges of the panel member I8 sd that when the panel member I8 is inserted in the recesses Il the rivets 22 are eiectually concealed.

The vertical Wooden members I4 of the frame 60 I2 are covered by vertical metal members 23. As illustrated in Fig. 2, each of the vertical metal members 23 encircles the associated vertical wooden member I4 of the wooden frame I2 and is provided with lips 24 which project parallel to each other and engage the surface of the panel member I3. These lips 24 of the vertical metal members 23 are secured to the panel member I8 by a continuous weld 25.

The horizontal wooden members I3 of the wooden frame I2 are likewise covered with horizontal metal members 23. Each` of the. horizontal metal members 2S also encircles the horizontal wooden member I3 of the frame I2 and isprovided with lips 2'I which project parallel to each other and engage and are welded to the Surface of the panel member I2 in a manner identical with that described relative to the attachment of the vertical metal members 23 to the panel member I3. The ends of the lips 2l of the horizontal metal members 23 and the ends of the lips 26., of the vertical metal members 23 are inclined at an angle of substantially 45 as indicatedV by the numerals 26a and 2id of Figs. 6 and 8 respectively, so that the inclined surfaces thus formed abut against each other.

As illustrated in Fig. 7, the vertical metal members 23 are made somewhat longer than the vertical wooden members It of the frame I2 by the extension of the sides of each metal member 23 to provide tabs 28, and by the extension of the end of each of the vertical metal members 23 to provide a trapezoidal projection 29. The horizontal metal members 26 are provided with tongues 32 formed by the extension of the upper and lower sides of the upper and lower horizontal metal members 26, respectively. As illustrated in Fig. 6, the tongue 3G is substantially trapezoidal and when a vertical metal member 23 and a horizontal metal member 26 are disposed around adjacent wooden members I4 and I3 of the frame I2, the tongue 33 is disposed over the end of the vertical wooden member Ill. The trapezoidal projection 29 of the vertical metal member 23 is then bent across the end of the vertical wooden member I4 of the frame I2 and the tabs 23 of thevertical metal members 23 are folded over the trapezoidal projection 29 and the tongue 3B into the position in which they are illustrated in Fig, 8. The end of the uppermost tab 28 is then welded Ato the other tab 28, as indicated by the numeral 3l of Fig. 8, and the intersecting sides of the tabs 28 are welded to the trapezoidal projection 29 for a short distance from'their intersection, as indicated by the numeral 32 of Fig. 8. The absence of a weld over the entire end of each of the tabs 28 provides some little space between the tabs 23 and the trapezoidal projection 29 of the vertical metal members 23 to permit the escape of any gases generated by the partial combustion of the wooden members I3 and it of the frame i2.

Formed in each end of that face of the vertical wooden members I4 of the frame I2 which is adjacent the panel member I3 are two grooves 33. As illustrated in Fig. 5, each of the grooves 33 is formed in the surface of the vertical Wooden member I4 adjacent the panel member I8 and in the adjoining side of the vertical wooden member Il. Each of the grooves 33 is of a length substantially equal to the vertical dimension of each of the horizontal wooden members I3, of a depth somewhat greater than the thickness of the metal sheets 29 and 2|, and of a width somewhat greater than its depth. As is illustrated in Fig. 6, the sides of each of the horizontal metal members 2S are of a greater length than the sides of the horizontal wooden members I3 of the frame I2 so that projections 34 of the horizontal metal members 26 overlap the vertical metal 5 members 23 over the grooves 33, as illustrated in Fig. 3.

The vertical metal members 23 and the horizontal metal members 23 being assembled in this manner around the frame I2, with the projections 34 ofthe horizontal metal members 26 overlying. the horizontal metal members 23, the projections 34 are secured to the vertical metal members 23 by a continuous weld, as indicated by the numeral 35 of Fig. 3. In the commercial production of the doors o f my invention, 'this weld 35 is apt to include many irregularities such as indicated at 3'3 in Fig. 3, which project above the upper surface of the projections 34. I therefore nd it desirable to subject this welded seam 201 members 23 or the horizontal metal members 25 23. As illustrated in Fig. 4, when the welded seam is forced into the groove 33 the outer surfaces of the metal members 23 and 23 provide, a crevice above the weld 35. This crevice 37 is filled with solder or other filler 38 which is then 30"' scraped down so that the filler 38 presents a surface continuous with the surface of the metal members 23 and 26. When the metal members 23 and 2G and the filler 38 are covered with paint or any other suitable medium the joint 35 between the metal members 23 and 26 is entirely invisible.

While I have described the door of my invention as including a panel member I8 covered with metal sheets 2D and 2I, it should be obvious that L a glass panel may be substituted for the panel member I2, or that the metal members 23 and 26 may be so formed as to cover the panel member i8 as well as the frame I2.

VThe steps in my method of manufacturing a door having a supporting structure and a metal envelope therefore include the steps of vforming grooves in the supporting structure, overlapping the elements of the metal envelope over these grooves, continuously welding the elements together at their overlap, grinding the weld, depressing the joint so formed into said groove, and filling the depression thus formed flush with the adjoining surface of the elements.

As has been previously pointed out, any gases 5;.

generated by the application of heat to the members of which the door is composed are allowed to escape between the tabs 23 and the trapezoidal projection 29 of the vertical metal members 29. Openings 39 may be provided in the metal members 23 communicating with the grooves 33 to further facilitate the escape of such gases. It is thus seen that I have by my invention provided a metal clad door which includes vent means for the escape of gases generated by the applica- 65 Y' door of my invention which might be damaged 75 v by contact with Water are completely encased in metal.

While that form of embodiment of my invention hereinbefore illustrated and described is fully capable of performing the objects and providing the advantages primarily stated, there are various other embodiments of my invention likewise capable of performing these objects and providing these advantages, and I therefore wish my invention to be understood as not restricted to the specic embodiment hereinbefore set forth.

I claim as my invention:

l. In a door, the combination of: a panel having sheet metal plates on either side thereof; a frame having a recess into which said panel projects; fastening means in said recess extending between said sheet metal plates and securing said sheet metal plates together; and a cover of sheet metal surrounding said frame and having its edges welded to said panel.

2. In a door, the combination of a panel having sheet metal plates on either side thereof; a frame having a recess into which said panel projects, said recess being of a width greater than the thickness of said panel; fastening means in said recess extending between said sheet metal plates and securing said sheet metal plates together; and a cover of sheet metal surrounding said frame and having its edges Welded to said panel, said cover being formed of a plurality of plates welded together in such a inanner that they present an unbroken outer surface.

3. In a door, the combination of an internal member having a groove in its outer surface; metal plates abutting against the outer surface of said member and having overlapping portions in said groove; a welded joint between said overlapping portions of said plates in said groove; and lling material covering said joint and lling'any irregularities therein so that the outer surface of said material is flush with the outer surface of said Plates.

4. In a door, the combination of t an internal member having a groove in one surface thereof; metal plates overlapping each other, said overlap being depressed in said groove; a continuously welded joint between said plates in said groove; and a lling medium on said overlap providing a surface above said groove fiush with the adjoining surfaces.

5. The method of manufacturing a door having a supporting structure and a metal envelope, which includes the steps of: forming grooves in said supporting structure, overlapping portions of said envelope over said groove, continuously Welding said overlapping portions, and depressing said welded overlap into said groove.

6. The method of manufacturing a door having a supporting structure and a metal envelope, which includes the steps of: forming grooves in said supporting structure, overlapping portions of said envelope over said groove, Welding said overlapping portions, depressing said welded overlap into said groove, and applying a filling to said welded overlap so that the outer surface of said filling is flush with the adjoining surface of said envelope.

7. rlhe method of manufacturing a door having a supporting structure and a metal envelope, which includes the steps of: forming grooves in said supporting structure, assembling the elements of said metal envelope upon said supporting structure so that the ends of adjoining elements overlap over said grooves, continuously Welding together adjacent elements at their 5 overlap, grinding the surface of the welded joints and depressing said welded joints into said grooves.

8. The method of manufacturing ya door having a supporting structure and a metal envelope which includes the steps of forming grooves in said supporting structure, assembling the elements of said metal envelope upon said supporting structure so that the ends of adjoining elements overlap over said grooves, continuously welding together adjacent elements at their overlap, grinding the surface of the Welded joints, depressing said Welded joints into said grooves, and applying to the depressions so formed a medium for concealing said welded joints.

9. The method of manufacturing a door having a metal exterior, which includes the steps of: assembling the metal elements of said door so that the ends of adjacent elements overlap, welding said elements together at the overlaps so formed, depressing the welded joints below the adjacent surface of said elements, and applying to said depression a filling medium until the surface of said medium is iiush with the adjacent surface of said elements.

l0. The method of manufacturing a door having a metal exterior, which includes the steps of: assembling the metal elements of said door so that the ends of adjacent elements overlap, continuously welding said elements together at the overlaps so formed, grinding the surface of the welded joints, depressing the welded joints below the adjacent surface of said elements, and applying to sai-d depression a filling medium until the surface of said medium is flush with the adjacent surface of said elements.

ll. A door comprising a supporting structure of combustible material and a metal envelope about said structure, the sides of said envelope being continuously welded, said envelope being provided with open vents for the escape of gas caused by the exposure of said combustible material to heat.

l2. In a door, the combination of: a panel having sheet metal plates on either side thereof; 50

a frame having a recess into which said panel projects, and having grooves therein; a cover of sheet metal surrounding said frame and having its edges welded to said panel, said cover being formed of a plurality of elements with the overlapping edges of adjacent elements welded together in said grooves; and gas escape vents communicating with said grooves.

13. In a door, the combination of: a panel having sheet metal plates on either side thereof; a frame of combustible material having a recess into which said panel projects, and having grooves therein; a cover of sheet metal surrounding said frame and having its edges continuously welded to said panel, said cover being formed of a plurality of elements with the overlapping edges of adjacent elements welded together in said grooves; and vents communicating with said grooves for the escape of gas generated by the exposure of said combustible material to heat.

THOMAS BEYRLE. 

